Powder Bed Additive Manufacturing Insert Placement
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Solution Overview
Problem
Existing methods for producing abrasive processing tools with statistically distributed hard material particles result in high tool mold wear and suboptimal distribution, leading to increased costs and reduced accuracy, prompting the need for more precise integration of insert elements during layered production.
Innovation Solution
A method for layered production of components from powdery material that involves partially removing loose powder particles to create cavities or support structures, allowing for the accurate integration of insert elements, such as cutting elements, by defining setting areas and using suction or blowing to remove excess powder, thereby maintaining the defined positions of these elements.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If hard material particles are statistically distributed in the green body, then the production process is simpler, but the tool mold wear increases and distribution accuracy deteriorates
Solution Approach 1:
The green body is segmented into N consecutive cylindrical cross-sectional areas along the building direction, with each cross-sectional area formed from a two-dimensional cross-sectional surface perpendicular to the building direction and a layer thickness in parallel to the building direction. This segmentation enables precise control of hard material particle distribution in each layer while maintaining manufacturing efficiency.
Solution Approach 2:
The method transitions from three-dimensional random distribution to layer-by-layer controlled placement. By dividing the green body into multiple two-dimensional cross-sectional areas and controlling particle placement in each layer, the invention achieves precise distribution accuracy while maintaining production simplicity through automated layer construction.
2Manufacturing precision
If hard material particles are arranged in defined positions in layers, then distribution accuracy is improved, but the complexity of arranging particles increases
Solution Approach 1:
The method applies powder layers and positions hard material particles in defined positions before final green body formation. By preliminarily arranging particles in each cross-sectional area during the layer construction phase, the system achieves precise distribution without requiring complex post-processing arrangement mechanisms.
Solution Approach 2:
The patent employs pneumatic methods for particle manipulation and placement. By using gas or liquid flow to transport and position hard material particles in defined locations within each powder layer, the system reduces mechanical complexity while maintaining high distribution accuracy through automated pneumatic control.
3Productivity
If application tools are used to apply and distribute powder layers, then production efficiency is improved, but hard material particles may be displaced from defined positions
Solution Approach 1:
The green body construction is segmented into discrete layers, with hard material particles positioned in defined locations within each layer before the next powder layer is applied. This layer-by-layer segmentation prevents particle displacement by isolating particles in each cross-sectional area and protecting them during subsequent powder application.
Solution Approach 2:
Hard material particles are preliminarily positioned in defined positions within each powder layer before subsequent layers are applied. This preliminary placement ensures particle stability and prevents displacement during the powder application process, maintaining both production efficiency and positioning accuracy.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This approach enables the precise and automated integration of insert elements with reduced risk of displacement during subsequent powder layer application, enhancing the accuracy and quality of the final product while minimizing the use of additional constituents like adhesives.
Implementation Method 1
The hard material particles are taken up with the aid of a suction plate and positioned over the layer structure
Implementation Method 2
By reducing the suction force or with the aid of a short compressed air blast, the hard material particles detach from the suction plate and are placed into the upper powder layer of the layer structure
Data Source
AI summary
A method for the layered production of a component (10) from powdery material including loose powder particles, based on three-dimensional data of the component (10), including the method steps: the component (10) is segmented in a building direction (16) into N, N≥2 consecutive, cylindrical cross-sectional areas (11, 12, 13, 14, 15) made up of a two-dimensional cross-sectional surface and a layer thickness; N powder layers of the powdery material are applied to a building plane perpendicular to the building direction (16); the loose powder particles in the cross-sectional areas (11, 12, 13, 14, 15) of the component (10) are at least partially bonded to each other and to the underlying cross-sectional area and; loose powder particles arranged within one cross-sectional area or within multiple consecutive cross-sectional areas in the building direction (16) are at least partially removed from the component (10) during the layered production of the component (10).